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Old 11-29-2010, 02:09 PM   #1
DirtJack OP
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Joined: Aug 2007
Location: San Antonio, Texas
Oddometer: 798
KTM 690e fuel pump (FI) issues

Just got back from several days of riding/camping in Terlingua Ranch and Big Bend Ranch State Park. Awesome weather (30's to 60's) and riding.

The problem is that the bike stopped a few times and a couple of times failed to start after stopping for a short while (this happened once before while riding in the Gila National forest earlier this year but now the problem seems to be getting worse).

When the problem occurs, you can tell that the bike will not start by turing the key to on. You can hear the fuel pump relay click but you do not hear the usual sound of the fuel pump spinning up to pressurize the fuel system. When this happens, no amount of cranking with the starter motor will start the bike; that just runs down the battery.

So how do I get it going again? Just wait. Sometimes a minute or two, sometimes 10 to 30 minutes. Eventually, when you turn the ignition on, you will hear the relay and then the friendly fuel pump sound and the bike will instantly start.

Whenever the bike does run, it runs as strong as ever. The problem is intermittent as the bike ran without any problems one day of this ride. The problem acts a bit like some sort of heat sensitivity, but it wasn't hot and the bike did not overheat. A couple of times the after-market 88 deg. C fan switch ran the radiator fan on slow gnarly hill climbs, but the fuel pump is in the tank cooled by the fuel.

Anyone have any ideas before I pull the fuel pump and filter assembly?

I've owned the bike since new and it now has about 11,000 miles on the clock.
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